Building construction



H. LIBBERTON ET AL May 8, 1934.

' i BUILDING CONSTRUCTION Filed April 30, 1930 46 Louis C pzazia d ,imlu/iwm/ Patented May 3, i934 PATENT OFFICE BUILDING CONSTRUCTION Herbert Libberton, Chicago, and Louis C. Piazza,

Western Springs, 111., assignors to The Soundex Corporation, Jolict, 111., a corporation of Illinois Application April 30, 1930, Serial No. 448,466

4 Claims.

This invention relates to wall construction, and more particularly to the construction of walls erein concrete or other plastic self -setting substances are used for sustaining the major por- 5 tion of the stress'on the wall. It is one of the objects of the present invention to provide an improved method of making such walls.

In the manufacture of buildings having walls of concrete or other similar substances, it is customary to first set up a form of wood or the like into which the concrete to form the wall is poured. The form material is generally of such a character that it can easily and quickly be reved before or after the concrete has fully hardened. In order to facilitate this action it has been customary to grease the forms thoroughly before using. After the concrete has partially or completely set the form is removed and brick,

side

other substances, is then applied to the outer of the wall in order to improve its appearance. It is also customary to apply some kind insulating material to the inner side of the wall. This is an ineficient and expensive way to make such walls since not only do the forms used represent a considerable capital outlay, but also the labor involved in the putting up and the taking down of the forms is considerable. Where insulating material is thereafter applied to the walls there is an additional labor expense involved. It is an object of the present invention provide a wall of the type indicated wherein side the concrete form, said heat insulating material constituting an integral part of the completed wall and becoming integrally united with the concrete upon the setting thereof.

The insulating material used comprises slabs of long fibrous substances loosely and promiscuously intertwined to present an irregular surface having a large number of small interstices into which concrete may pass to rigidly unite the concrete with the form. The long fibers constituting the insulating slab are held together by a suitable binder.

In the pending application of Herbert Libberton, Serial No. 429,587, filed February 19, 1930, there is described a method of making a slab such as may be used in connection with the present invention, although the slab of the present invention may be made in any other preferred manner, and likewise may be made of material other than that described in the above application.

The insulating slabs constitute one side of the for m for the concrete and the other side of the form is made of metal lath. Any form of expanded or wire metal lath may be used, it being preferred that the openings in the metal lath be not too large. The metal lath and the slabs are tied together in spaced relationship by suitable brackets in order to prevent bulging of the lath. Concrete is then poured into the space between the two wall sections, said sections constituting a form for retaining the concrete. The general practice in the use of metal lath for stucco has been the application of a two inch mesh lath, so that the stucco will penetrate in and around the steel, protecting it, so far as possible, from the weather. This practice has the disadvantage that there is such large volume of steel present that if it becomes wet and rusts the increase in volume is so great as to cause spalling of the stucco. This is not true with the thinner lath such as is recommended for use in connection with the present invention since, with such lath, there is so little volume of steel at any one place that it could even rust out entirely without causing spalling of the plaster.

Another point in this connection is the fact that two inch mesh applied in the ordinary way to buildings gives a very wavy effect which is counteracted to certain extent by the plasterer applying the stucco. This results in very thin protection for the steel at some points and very thick at others. Busting at the thin points is almost inevitable. With the construction of this invention there is less tendency for the mesh to wave since the ribs so stiffen the form as to make this practically impossible. But even though the stucco were applied too thinly at any one spot it would be impossible for it'to spall because of the excellent bond with the rough concrete in the Vicinity.

The concrete or other plastic material used enters into the interstices at the surface of the slab and upon setting forms a secure bond therewith. Likewise the concrete passes into the openings in the metal lath and forms a secure bond therewith upon setting. The metal lath may constitute the outer side of the wall and the insulating slab the inner side. Stucco, or other decorative material, may then be applied to the outer surface of the wall and interior plaster or the like may be applied to the inner surface of the wall. 1

We provide an improved tie bracket for use in wall construction as above set forth. The bracket is preferably L shaped with one side thereof in contact with the metal lath. One side of the bracket may have a number ofpunchings formed therein along its length whereby it may be rigidly secured to the lath although the punchings may be dispensed with and ordinary wires be used to secure the brackets to the lath. The end of one of the other sides has a number of holes formed therein for receiving double ended nails for securing the bracket and the insulating slabs together, or the end of the bracket maybe provided with a number of pointed projections thereon whereby it may be readily secured to an insulating slab. The bracket is preferably arranged to be secured between two adjacent slabs. being secured to both of them and thereby also securing the slabs together.

The attainment of the above and'further object of the present invention will .be'apparent from the following specification taken in-conjunction with the accompanying-drawing forming a part thereof.

In the drawing:

Figure 1 is a top plan view of a wall constructed in accordance with our invention, said view being taken along the line 11- of Figure2 andlooking in the direction of the arrow;

Figure-"2 is a transverse sectional --view of the wall, said View being taken along the line 2-2 of Figural;

"Figure 3 is aperspective view showing apair 'of'clips such as maybe used inthe'wall shown inFigure l, and illustrating the manner inwhich the 'clips are secured together;

Figure '4 is a transverse sectional -view taken along the -line"44-o f Figure 3 an'dshowing the manner in which thespacingclips are secured together;

Figure '5 is a view of the back of a modified form of tie clip;

Figure 6is a-sect-ional-view-taken a-long'the line "6 6 -or "Figure 5;

"Figure"? "is 'a fragmentaryperspective view of another form of'clip;

Figure8 is aside view of still another form of clip;

Figure '9 is a perspective view of a pair ofclips of a construction somewhat different from that shownin Figure 3; and

T Figure 10 is a view of a double ended nail used in'connection with the clips of- Figure 10.

Reference may now behad more particularly to Figures land 2 showing a fragmentary portion of a wallconstructe'd inaccordance with the principles 'of our invention. In this embodiment thewall'comprises one portion indicated at 1 formed of insulating slabs; asshown at 2,3 and 4. These slabs are generally-rectangular and about 2"" thick, the sides being 'about'lfi by'48", although it is to be'understood that the invention is not limited to the use of a slab of this'size as the slab may be made of any size desired. The slabs are heat insulating .and are, preferably, although not necessarily,.for.med of-long fibrous materiaLsuch as excelsior or the like, promiscuously intertwined-and-held together by a-suitable binder. A'method of making such slabs is shown in' the pendingapplication of Herbert Libberton,

Serial 'No. 429,587, filed'Februaryil9, 1930, to which reference may be had fora :more. complete descri-ption of a method offmakingislabs such :as are suitable for use in connection with a wall :as shown in this application. The *presentinvention'is, however, not limited'to the use of any particular kind of slab, nor is it limited to the use of 'slabs made by a process such as is referred to in the above application. It is only essential that'the slabs used shall have a surface texture of such a character as to cause it to adhere to concrete rather than to part from it.

It is also preferable that the slabs used be of heat insulating material. In the slab shown the fibers are loosely and promiscuously intertwined so that the surface of the slab has a large number of interstices into which'concrete or the like may enter. The slabs 2,-3, and 4 are built up to form a wall, said slabs being laid with the ends in adjacent rows staggered in the same manner that the bricks are laid. A metal lath 6 is mounted in spaced parallel relationship to the wall portion 1. The metal lath 6 is held in position in spaced relationship to the wall portionl by means of tie clips or brackets 8 that are secured to the wall portion 1 and to the metal lath. The bracket shown may be L shaped and comprise a'horizontal portion 10 and a vertical portionll. The tie clip or bracket may be of a construction such as is shown more particularly in FIgures' F, to"7. The form of bracket shown in Figures-sand 4 is an L shaped channel'section and is formed of metal. The flanges of the channel are cutaway adjacent theend of the'horizontal portion 10 as indicated at 15, and the end of the base portion is slit centrallyffor a short distance and the-opposite ends bent in opposite directionsgas indicated at 1'7 and 18. 'The ends 1'7 and 18 are 'pointed to'facilitate their insertion into a slab in the same manner thata nail is inserted into a yielding object. The tie clips or brackets 8'm-ay' be arranged in vertical alignment with adjacent vertically aligned brackets secured together. This is illustrated 'inFigure 3. With this arrangement it Will-be apparent that the brackets may serve as studs in addition to performing: their function as tie means.

The flanges of the channel of thever'tical porticn'll of the'bracket are forced outward slightly,

thus 1 permitting the insertion of the base of another bracket into the same. This is illus trated atF-igures3 and 4. The flanges of-the' two channels that have been inserted into oneanother arethen bent inward, thus crimping"the twotogether. et-"has s n-umber of "holes 20 formed therein:in spaced relationship. The holes in the two brack ets are'br-ought together and then the brackets rnay be secured by means of a wire or'the like;

The'distance from the ends l5 of the flanges to the pointed portions Hand 19 is equal to one-half of the thickness of an insulating slab, and the bracket is brought against the slabwith the point 18 at the center of aslab. The point 18 is then forced-into the slab with the point 17 extending upward. Another slab is i then brought down above the first slab and upon being forced downward the end'17 enters the center 'of the bottom portion of that slab. The portions 15 of the flanges-bear against the inner si'des of the; slabs. The vertical portion'll of the tie bracket is secured to the metal lath 6 in any desired manner. The-'channel'may be of such a small cross-sectionalareaas toipermit insertion thereof through the openings in the metal lath, or if it is too large to secure to the lath in that manner itmay be tied to the lath by means of wiresorthe like.

"The" tie brackets effectivelypreventbulging of the lath. Concrete or other self-setting plastic material may then be poured into the space between the 'Wall portion 1 and the lath portion 6. These portions act as a form for the concrete and the concrete rigidly units itself to the insulating slab because of the large number of small IlI lO In addition the portionll of the-:brackinterstices in the slab. Likewise-the concrete ter of the nail hole extends into the top of that firmly embeds itself in the metal lath due to the large number of small openings in the lath. It is to be noted that the bracket ties do not come into contact withthe facing material that may be placed on the oute side of the wall 1, but are driven into the center of the'slab. This eifectively prevents any possibility of condensation at the end of the tie bracket.

Reference may now be had to Figures 5 and 6 showing a portion of a modified form of bracket which in general is similar to tha; shown in Figure 3. The bracket is channel shaped, as shown in Figure 3, and at its back portion 11 has a numoer af stamping or punchings 25 formed therein. These permit the ready securing of the tie bracket to the metal lath since the expanded portions 25 may be forced into one of the openings in the lath and then upon moving the bracket downward it becomes rigidly secured to the lath. In other detail this bracket may be the same as that shown in Figures 3 and 4.

Figure 7 shows still another form of a bracket which is of small L shaped cross-section. Other Wise this bracket is essentially similar to that shown in Figures 3 and 4. This bracket has a number of holes 2-3 formed at the corner of its vertical portion 11 for facilitating the securing of adjacent brackets together. These holes correspond in function to the holes 20 of Figure 3. The base portion 10 of this bracket has a downwardly formed stamping formed therein and an upwardly formed stamping 31 also formed therein. At the end of the bracket is formed a nail hole 32. The distance between the cenand the portion 36 is equal to about one-half of the thickness of an insulating slab. When this bracket is used the portion 35 is rested upon the top part of an insulating slab with the portion 30 thereof restin against the side of the slab. A may then be driven through the hole 32 to rigidly secure the bracket to the top of the slab. The upper end of portion 31 is pointed in order to enable the same to readily embed itself in an insulating slab that is mounted on top of the slab whereon the bracket rests. It is to be noted that the end or" the L shaped bracket is flattened in order to provide a greater surface area for the portion 30 and the portion 31.

If desired the bracket may be made as shown in Figure 8. This bracket is than L shaped. It may be of channel crosssection or of an L shaped cross-section, as shown in Figure 3 or in Figure '2. In this form of bracket the base portions 46 and a1 are spaced apart by a vertical portion e2 which is of a height exactly equal to the height of one of the insulating slabs and the prong 4.5 extends into the bottom of one of the slabs and the prong 46 same slab. In addition this clip is provided with a lower prong 48 which extends into the slab below that into which the prong 45 is embedded and the clip'is provided with a prong 49 that extends into the slab above that into which the prong 46 is inserted.

In other detail this bracket may be the same as that shown in any of the other figures. When a bracket, such as is shown in Figure 8, is used then the brackets are not mounted in vertical alignment but rather they are staggered and therefore it is not necessary to secure together two vertically spaced brackets.

Stucco, brick veneer, stone, or other material may be applied to the outer side of the wall in order to improve its appearance. Likewise side of the wall.

U shaped rather I plaster or the like may be'applied to the inner This is indicated, in connection With'the metal lath 6, at 56.

While we have herein shown a wall wherein concrete is poured between the two wall sections, it is to be understood that we are using the term concrete in its broadest sense and intend to include thereby any cementitious material that may be poured into a form such as is here shown. This includes the use of gypsum, Portland cement or the like.

In Figure 9 we show an improved form of wall tie bracket which may be used in a wall construction such as is shown in Figuresi and 2. This bracket is formed of a bar of metal having a generally V-shaped cross-section and bent into an L,shape. The vertical leg 60 of the bracket is secured to the metal lath in any preferred manner. For instance, it may be tied thereto at a plurality of spaced points along its length by means of tie wires. tends from the metal lath to the insulating slab and is flexed at the end as indicated at 62. The flexed end is provided with one or more spaced holes as indicated at 63 and 64 to facilitate the securing of the bracket to the insulating slab. The flexed end 62 of the bracket is placed between two adjacent slabs of insulating material in the manner shown in Figure 2 and is secured to both of the slabs by means of a double headed nail such as is shown in Figure 10. The flat end 62 is placed on top of one slab and the long end 66 of the nail shown in Figure 2 is driven through the opening 63 in the tie bracket until the flat portion 67 of the nail abuts against the tie bracket. The short end 68 of the nail projects upward from the flattened portion 52 of the bracket and a second insulating slab may be brought down on top of the first one, said portion 68 of the nail entering into the upper slab and thereby securing the two slabs together. Where two nails are used the second nail may, if desired, be reversed so that its short end 68 extends downwardly and its long end 66 extends upwardly. This, of course, is optional. This form of tie bracket is preferable to the brackets previously described in that it is cheaper to make and the amount of labor involved in setting the same up on the job is also less than that involved in connection with the use of the other bracket here shown.

in compliance with the requirements of the patent statutes we have herein shown and described a few preferred embodiments of our invention. It is, however, to be understood that the invention is not limited'to the precise con struction herein set forth, the same being merely illustrative. What we consider new and desire to secure by Letters Patent is:

1. A concrete form, one side of which comprises a series of insulating slabs and the other side of which consists of metal lath and tie brackets securing said sides in spaced relation. said brackets being secured to said slabs by means of pointed fastenings inwardly of the outer face of said slabs and consisting of L shaped channel members, the vertical portions of which are nested and serve as studs to prevent bulging of the lath.

2. A building wall comprising spaced form sections, one of said sections including a plurality of porous insulating slabs, the other of said sections consisting of metal lath tie brackets securing said sections in spaced relation, said brackets being secured to said slabs by means of pointed fastenings inwardly of the outer face of saidslabs The horizontal leg 61 exand consisting of L shaped channel members, the vertical portions of which are nested and serve as studs to prevent outward bulging of the lath and the intermediate portion comprising concrete poured into the space between said sections and surrounding portions of saidtie brackets.

3. A concrete form, one side of which comprises a series of insulating slabs and the other side of which consists of metal lath and tie brackets securing said sides in spaced relation, said brackets being secured to said slabsby meansdisposed inwardly of the outer face of said slabs and consisting of L shaped members, the verticalportions of which are nested and serve as studs to prevent bulging of the lath.

4. A building wall comprising spaced form sections, one of said sections including a plurality of porous insulating slabs, the other of said sections consisting of metal lath, tie brackets securing saidsections in spaced relation, said brackets being secured to said slabs by means disposed inwardly of the outer face of said slabs and consisting of L shaped members, the vertical portions of which are nested andserve as studs to prevent outward bulging of the lath and the intermediate portion comprising concrete poured into the. space between said sections andsurrounding portions of said tie brackets.

HERBERT LIBBERTON. LOUIS C. PIAZZA. 

